DE60317589T2 - Air cushion laminate with a barrier layer of recycled polyester - Google Patents

Air cushion laminate with a barrier layer of recycled polyester

Info

Publication number
DE60317589T2
DE60317589T2 DE60317589T DE60317589T DE60317589T2 DE 60317589 T2 DE60317589 T2 DE 60317589T2 DE 60317589 T DE60317589 T DE 60317589T DE 60317589 T DE60317589 T DE 60317589T DE 60317589 T2 DE60317589 T2 DE 60317589T2
Authority
DE
Germany
Prior art keywords
film
multilayer film
barrier layer
layer
inner
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Active
Application number
DE60317589T
Other languages
German (de)
Other versions
DE60317589D1 (en
Inventor
Plainsboro Freundlich Richard
North Caldwell Kannankeril Charles
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Sealed Air Corp
Sealed Air Corp (US)
Original Assignee
Sealed Air Corp
Sealed Air Corp (US)
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority to US82635 priority Critical
Priority to US10/082,635 priority patent/US20030161999A1/en
Application filed by Sealed Air Corp, Sealed Air Corp (US) filed Critical Sealed Air Corp
Application granted granted Critical
Publication of DE60317589D1 publication Critical patent/DE60317589D1/en
Publication of DE60317589T2 publication Critical patent/DE60317589T2/en
Application status is Active legal-status Critical
Anticipated expiration legal-status Critical

Links

Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00Ancillary operations in connection with laminating processes
    • B32B38/06Embossing
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00Layered products comprising a layer of synthetic resin
    • B32B27/32Layered products comprising a layer of synthetic resin comprising polyolefins
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00Layered products comprising a layer of synthetic resin
    • B32B27/36Layered products comprising a layer of synthetic resin comprising polyesters
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form ; Layered products having particular features of form
    • B32B3/26Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form ; Layered products having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
    • B32B3/28Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form ; Layered products having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by a layer comprising a deformed thin sheet, i.e. the layer having its entire thickness deformed out of the plane, e.g. corrugated, crumpled
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/06Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the heating method
    • B32B37/065Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the heating method resulting in the laminate being partially bonded
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B65CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65DCONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D81/00Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents
    • B65D81/02Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents specially adapted to protect contents from mechanical damage
    • B65D81/03Wrappers or envelopes with shock-absorbing properties, e.g. bubble films
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C2791/00Shaping characteristics in general
    • B29C2791/001Shaping in several steps
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/001Combinations of extrusion moulding with other shaping operations
    • B29C48/0012Combinations of extrusion moulding with other shaping operations combined with shaping by internal pressure generated in the material, e.g. foaming
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/001Combinations of extrusion moulding with other shaping operations
    • B29C48/0017Combinations of extrusion moulding with other shaping operations combined with blow-moulding or thermoforming
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/001Combinations of extrusion moulding with other shaping operations
    • B29C48/0021Combinations of extrusion moulding with other shaping operations combined with joining, lining or laminating
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/07Flat, e.g. panels
    • B29C48/08Flat, e.g. panels flexible, e.g. films
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/13Articles with a cross-section varying in the longitudinal direction, e.g. corrugated pipes
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/16Articles comprising two or more components, e.g. co-extruded layers
    • B29C48/18Articles comprising two or more components, e.g. co-extruded layers the components being layers
    • B29C48/21Articles comprising two or more components, e.g. co-extruded layers the components being layers the layers being joined at their surfaces
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/18Thermoforming apparatus
    • B29C51/20Thermoforming apparatus having movable moulds or mould parts
    • B29C51/22Thermoforming apparatus having movable moulds or mould parts rotatable about an axis
    • B29C51/225Thermoforming apparatus having movable moulds or mould parts rotatable about an axis mounted on a vacuum drum
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29KINDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/04Condition, form or state of moulded material or of the material to be shaped cellular or porous
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29LINDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2009/00Layered products
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29LINDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00Other particular articles
    • B29L2031/712Containers; Packaging elements or accessories, Packages
    • B29L2031/7138Shock absorbing
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2305/00Condition, form or state of the layers or laminate
    • B32B2305/30Fillers, e.g. particles, powders, beads, flakes, spheres, chips
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2305/00Condition, form or state of the layers or laminate
    • B32B2305/70Scrap or recycled material
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00Properties of the layers or laminate
    • B32B2307/70Other properties
    • B32B2307/724Permeability to gases, adsorption
    • B32B2307/7242Non-permeable
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2309/00Parameters for the laminating or treatment process; Apparatus details
    • B32B2309/14Velocity, e.g. feed speeds
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2323/00Polyalkenes
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2367/00Polyesters, e.g. PET, i.e. polyethylene terephthalate
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/08Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the cooling method
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/14Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B32B37/15Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer being manufactured and immediately laminated before reaching its stable state, e.g. in which a layer is extruded and laminated while in semi-molten state
    • B32B37/153Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer being manufactured and immediately laminated before reaching its stable state, e.g. in which a layer is extruded and laminated while in semi-molten state at least one layer is extruded and immediatly laminated while in semi-molten state
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02PCLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P70/00Climate change mitigation technologies in the production process for final industrial or consumer products
    • Y02P70/10Greenhouse gas [GHG] capture, material saving, heat recovery or other energy efficient measures, e.g. motor control, characterised by manufacturing processes
    • Y02P70/26Greenhouse gas [GHG] capture, material saving, heat recovery or other energy efficient measures, e.g. motor control, characterised by manufacturing processes related technologies for working on or processing of plastics
    • Y02P70/277Greenhouse gas [GHG] capture, material saving, heat recovery or other energy efficient measures, e.g. motor control, characterised by manufacturing processes related technologies for working on or processing of plastics relating to thermoforming
    • Y02P70/279Recycling or reuse of materials
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/24Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24628Nonplanar uniform thickness material
    • Y10T428/24661Forming, or cooperating to form cells

Description

  • FIELD OF THE INVENTION
  • The The present invention relates generally to a cellular (cellular, cellular) upholstery article made of laminated films and methods of making such a cellular cushioning article. The cells of the cushioning article are either at the time the lamination of the films filled with fluid, or it is during the Lamination formed a series of uninflated cells, wherein These cells are inflatable by an inflation channel, the one Variety of cells in a row connects.
  • BACKGROUND OF THE INVENTION
  • Commercial Bubble Wrap® Upholstery Material uses two films laminated together. Typically, only one of the films is stamped, ie, thermoformed, in a manner to provide a plurality of protrusions when viewed from one side of the film, the protrusions being voids when viewed from the other side of the film. These projections are generally regularly spaced and have a cylindrical shape with a round base and an upper dome. The formed film is generally laminated to a flat film to form the product with air-filled cells. In another version, two molded films are laminated together to form the cellular product.
  • To provide the air-cellular product with fluid retention properties, e.g. B. air conditioning properties to provide, both films that are laminated together, a barrier layer on. In the past, the films used to make Bubble Wrap® cushioning material included a polyamide barrier layer and polyolefin layers on both sides of the polyamide layer. While the polyolefin layers are present to allow the films to be heat sealed together, the polyamide layer is present because polyamide has a crystalline structure that retards the gas transmission rate through the film. However, polyamide is a relatively expensive polymer. It would be desirable to provide the film with a barrier layer using a less expensive polymer.
  • SUMMARY OF THE INVENTION
  • It has been found to be used in a multilayer film for the production of a cellular Air cushion recycled polyester used as a barrier layer can be. It has been found that recycled polyester as Inner layer in combination with polyolefin polymer are coextruded can that be in the outer layers the film is used. It has been found that recycled polyester about 14 ° C (25 ° F) below the temperature at virgin Polyester can be processed, processed (i.e. extruded, molded, etc.). This difference in processing temperature of 14 ° C (25 ° F) compatible with the processing of the polyolefin-based polymers, in the outer heat seal layers of Multilayer film are present. The increased processing temperature of virgin Polyester leads to poor compatibility properties, if with significantly lower melting olefin-based polymers is processed.
  • It It has also been found that recycling of polyester, though the molecular weight of the polyester is reduced (and thus the Processing temperature reduced relative to young mellow polyester is), the barrier properties of the resulting barrier layer not significantly reduced. The layer of recycled polyester serves as an air barrier, especially as a barrier to atmospheric Nitrogen, oxygen, carbon dioxide, etc. The barrier layer is used because air-filled Upholstery cells during of use, resulting in "creep", d. H. Loss of gas from the cell, causing the cell of its cushioning task can do less justice. In other words, the barrier layer wears to help the gas during of use in each cell. Recycled polyester is also significantly cheaper than virgin polyester. preferred Film structures are five-layered Films with outer layers, the heat sealable Containing polyolefin, with a core layer containing the recycled polyester, and Interconnecting layers between the core layer and the polyolefin layers. The Tie layers contain a polymer that attaches to the polyolefin the polyester can stick, such as anhydride-modified polymer (eg. Anhydride modified linear low density polyethylene).
  • In addition to conventional upholstery items, such as thermoformed sealed laminate polyester articles, the present invention includes the use of recycled polyester in inflatable cushioning articles, transported in the deflated condition to the end user can be after which they are inflated immediately before use. This inflatable Cushioning articles are typically made from two flat unshaped heat-sealable films produced, which fused together in discrete areas to form one or more inflatable chambers.
  • Conventional processes for the production of upholstered articles such as Bubble Wrap ® cushioning material, use a vacuum source to the polymer film to form bubbles or pockets to deform, which can be filled with air (or other gases) to form bubbles. Such products can be made using a heated drum with recesses connected to a vacuum source. When vacuum is applied, each of the different regions of the heated film in contact with the drum is drawn into a depression on the drum. Those portions of the heated sheet that are pulled into the recesses are deformed and thinned by the vacuum drawing process. One side of the resulting molded element provides a flat surface for lamination thereto, ie it has a flat bottom portion with spaced concavities from the molding process, while the other side does not provide a flat surface for lamination, but molded protrusions with one (ie for lamination ) has unreachable flat bottom at the base of the projections. A second film, which is preferably a flat film, ie, not thermoformed, is melted to the "flat side" of the formed film, resulting in a plurality of sealed air-filled "bubbles". The fusion is preferably carried out by heat sealing.
  • Conventional upholstery manufacturing processes also include a first stage film extrusion step, an optional second stage film forming step, and a third stage film laminating step, wherein the steps are performed in a single integrated process, as in US Pat US 3,294,387 by Chavannes entitled "Laminated Cellular Material" and U.S. Patent Application Serial No. 09 / 934,732 to Kannankeril et al. entitled "Integrated Process for Making Inflatable Article". Polymeric films are extruded in the first stage by conventional techniques known to those skilled in the polymer film making art. In the second stage, one or more of the films is formed by the vacuum forming technique described above, and two films are combined into shaped sealed "blisters" by heat sealing techniques known to those skilled in the polymer film sealing art sector.
  • The present invention in a first aspect relates to a cellular cushioning article comprising (A) a first multilayer film having first and second outer layers each containing an olefin-based polymer and an inner O 2 barrier layer, and (B) a second multilayer film having first and second outer layers each containing an olefin-based polymer and an inner O 2 barrier layer. The first multilayer film is laminated to the second multilayer film so that a plurality of cells are formed between the first multilayer film and the second multilayer film. The inner O 2 barrier layer in the first film and / or the inner O 2 barrier layer in the second film contains recycled polyester.
  • In at least one of the first and second multilayer films each of the outer layers of both the first film and the second film preferably at least one member selected from the group consisting of low density polyethylene, linear Low density polyethylene, very low density polyethylene and homogeneous ethylene / α-olefin copolymer.
  • The The first film and / or the second film further comprises a bonding layer between the first outer layer and the barrier layer and a bonding layer between the second outer layer and the barrier layer. The first film and / or the second film preferably have the composition and / or the layer thickness a symmetrical layer structure.
  • Preferably For example, one or more of the tie layers include at least one Member selected from the group consisting of anhydride-modified polymer, e.g. B. Ethylene / unsaturated ester copolymer and ethylene / unsaturated Acid copolymer, and anhydride-modified Ethylene / α-olefin copolymer, such as anhydride modified linear low density polyethylene.
  • at an alternative preferred inflatable cushioning article the first multilayer film a flat unshaped film, and the second multilayer film is a flat unshaped film. The first and second films are preferably to form a plurality of cell rows sealed together, each of the cell rows one Variety of cells and a passageway that covers the cells connecting with each other in series. Each row has a dead end, where the passage and the cells in the row through an inflation fluid be inflated. The passage is sealed after inflation, so the cells in the row remain inflated.
  • In another preferred inflatable cushioning article, a plurality of discrete cavities are formed at spaced intervals with a base region therebetween in the first film, the second film being a flat film adhered to the first film in the base region, the first and second films in each of the discrete cavities, include a fluid. Alternatively, a plurality of discrete cavities are formed at spaced intervals in both the first film and the second film, each of the films having a base region between the discrete cavities, at least a portion of the base regions of the films being adhered to each other, and the cavities of the first and second slides contain a fluid. The cavities of the first and second films may be of identical size and have identical spacing from each other or be of a different size and / or have a different spacing. The cavities of the first and second films may be aligned (ie, so that the cavities of the first film overlap with the cavities of the second film), whereby the base regions also come into alignment with each other. Alternatively, the cavities may not be aligned or partially aligned with each other.
  • The Barrier layer of the first film and / or the second film comprises in one embodiment Mixture of recycled polyethylene terephthalate and virgin Polyethylene terephthalate.
  • According to one Second aspect, the present invention relates to a method for producing a cushioning article, wherein (A) a first multilayer film with first and second outer layers, each containing an olefin-based polymer and an inner one Barrier layer, the recycled polyester contains is extruded and (B) a second multilayer film with first and second outer layers, each containing an olefin-based polymer and an inner one Barrier layer that contains recycled polyester, extruded and (C) the first and second multilayer films are glued together, so that a multiplicity of cells is formed.
  • The The method further comprises according to a preferred embodiment forming a plurality of discrete cavities in the first film in spaced apart Intervals with a basic area in between. The cavities become after which the first multilayer film was extruded, however before the first multilayer film to the second multilayer film was glued. The basic area of the first film is then attached to the second film glued, leaving the first and second film when the first and second multilayer film are glued together include a fluid in each of the discrete cavities. The Molds are preferably made by passing the film over a Forming roller is passed, the discrete areas of the film in forming cavities pulls by the atmosphere evacuated from areas between the film and the molding cavity becomes. The fluid is preferably air.
  • In In a variant of this method, a plurality of discrete cavities are formed in both the first multilayer film as well as the second multilayer film formed, wherein the plurality of discrete cavities in spaced Intervals with a basic area in between. The shaping will after extruding the first and second multilayer films, however before the first multilayer film is adhered to the second multilayer film is, with the basic area of the first film to the basic area the second foil is glued so that the first and second foil, when the first and second multilayer films are adhered to each other, together include a fluid in each of the discrete cavities. Of the Basic area of the first film is preferably at the base area the second foil is heat sealed.
  • In another embodiment of the method, the first and second foils are heat sealed together, to form a plurality of cells, each of the rows of Cells contain a variety of cells and a passage that connecting the cells together, leaving an inflatable object is produced. Every row of cells has a dead end. The passage and the cells in the row can be inflated by an inflation fluid. The passage can be sealed so that the cells in each row remain inflated can. The inflatable article preferably has an open edge region at one edge in the machine direction.
  • BRIEF DESCRIPTION OF THE DRAWINGS
  • The Numerous features and advantages of the invention will become apparent to those skilled in the art better understood by the detailed description and the figures, in which
  • 1 FIG. 4 is an exploded perspective view of a first preferred cushioning article of the invention; FIG.
  • 2 a cross-sectional view through section 2-2 in 1 is
  • 3 Fig. 1 is a diagram of a method for producing a first cushioning article according to the invention;
  • 4 Figure 3 is a perspective view of an alternative preferred embodiment of an inflatable cushioning article of the invention;
  • 5 is a flattened plan view of an assembled embodiment of the embodiment of 4 corresponds, and
  • 6 a schematic of a method for producing the inflatable cushioning article according to 4 and 5 is.
  • DETAILED DESCRIPTION
  • "Film" is used here in the most general sense, so that all plastic web materials un depending on whether they are film or film. Films according to the invention and used according to the invention preferably have a thickness of 0.25 mm or less. The term "packaging" as used herein refers to packaging materials used to package product.
  • Of the The term "polyolefin" refers to here to any polymerized olefin that is linear, branched, cyclic, aliphatic, aromatic, substituted or unsubstituted. In the term polyolefin are specifically homopolymers of olefin (eg high density polyethylene and low density polyethylene), Copolymers of olefin, copolymers of olefin and non-olefinic Comonomer which is copolymerizable with the olefin, such as vinyl monomers, and modified polymers thereof. For specific examples belong Polyethylene homopolymer, polypropylene homopolymer, polybutene, ethylene / α-olefin copolymer, Propylene / α-olefin copolymer, Butene / α-olefin copolymer, Ethylene / vinyl acetate copolymer, ethylene / ethyl acrylate copolymer, ethylene / butyl acrylate copolymer, Ethylene / methyl acrylate copolymer, ethylene / acrylic acid copolymer, ethylene / methacrylic acid copolymer, modified polyolefin resin, ionomer resin, polymethylpentene, etc. Modified polyolefin resin includes modified polymer, by copolymerizing the homopolymer of the olefin or copolymer of which with unsaturated carboxylic acid is prepared, for. For example maleic acid, fumaric acid, or a derivative thereof, such as the anhydride, ester or metal salt. It can also by incorporation of unsaturated carboxylic acid, eg. For example maleic acid, fumaric acid, or a derivative thereof, such as anhydride, ester or metal salt, be obtained in the olefin homopolymer or copolymer.
  • As used herein, the term "ethylene / α-olefin copolymer" and "ethylene-α-olefin copolymer" refers to such heterogeneous materials as linear low density polyethylene (LLDPE) and very low and ultra low density polyethylene (VLDPE and ULDPE) and homogeneous Polymers such as metallocene catalyzed linear homogeneous ethylene / α-olefin copolymer resins such as EXACT available from Exxon Chemical Company and linear homogeneous ethylene / α-olefin copolymer resins such as TAFMER available from Mitsui Petrochemical Corporation. All of these materials generally include copolymers of ethylene with one or more comonomers selected from C 4 to C 10 alpha-olefins such as butene-1 (ie, 1-butene), hexene-1, octene-1, etc. where the molecules of the copolymers comprise long chains with relatively few side chain branches or crosslinked structures. This molecular structure differs from conventional low and medium density polyethylenes, which are more highly branched than their respective counterparts. The commonly known as LLDPE heterogeneous ethylene / α-olefins have a density which is usually in the range of about 0.91 g / cm 3 to about 0.94 g / cm 3. Other ethylene / α-olefin copolymers, such as the long chain branched ethylene / α-olefin homogeneous copolymers, available from Dow Chemical Company, known as AFFINITY resins, are known as another type of homogeneous ethylene / α- type useful in the present invention. Olefin copolymer also included.
  • The term "barrier" and the term "barrier layer" as used herein on films and / or film layers are used in terms of the ability of a film or film layer to serve as a barrier to one or more gases. In the packaging art, oxygen barrier layers (ie, gaseous O 2 ) generally include, for example, ethylene / vinyl alcohol copolymer, polyvinyl chloride, polyvinylidene chloride, polyamide, polyester, polyacrylonitrile, etc. However, in the present invention, the barrier layer comprises recycled polyester.
  • The The term "connecting layer" here means any inner layer with the main purpose of joining two layers together glue. Connecting layers can comprise any polymer having a polar group grafted thereon, such that the polymer is covalently attached to polar polymers, such as polyesters, can bind while It can simultaneously bind to nonpolar polymers such as polyolefin. Exemplary tie layer polymers include anhydride-modified Polyolefin (in particular anhydride-modified linear polyethylene low density), ethylene / unsaturated Ester copolymer (eg vinyl acetate copolymer, ethylene / butyl acrylate copolymer, Ethylene / methyl acrylate copolymer), Ethylene / unsaturated Acid copolymers (eg, ethylene / acrylic acid copolymer, Ethylene / methacrylic acid copolymer).
  • Of the Term "polyester" closes here Poly (ethylene terephthalate), poly (butylene terephthalate), poly (cyclohexane-1,4-dimethylene terephthalate), Poly (4,4'-isopropylidine-diphenyl carbonate), Poly (4,4'-carbonato-2,2-diphenylpropane) as well as other polyesters. The term "polyester" includes both virgin Polyester as well as recycled polyester.
  • The articles of the invention contain recycled polyester. While the recycled polyester may constitute up to 0.1 to 100 weight percent of the polyester present, the recycled polyester may be present in any amount in a blend with virgin polyester. However, the article preferably contains recycled polyester in an amount of about 10 to 100 wt .-% recycled polyester, based on the total weight of the existing polyester, in particular 30 to 100 wt .-%, in particular 60 to 100 Wt .-%. Recycled polyesters may also be either recycled film grade polyester (also known as polyester film grade recycled polyester) or bottle grade recycled polyester, and any virgin polyester may be present.
  • polyester of film quality usually has an intrinsic viscosity in the range of 0.8 to 1.35 dl / g (preferably 0.8 to 1.25), while polyester of Bottle quality usually an intrinsic viscosity of 0.8 dl / g or less (preferably 0.65 to 0.8). virgin Polyester usually has a higher one shear thinning as recycled polyester. virgin For example, polyester having an intrinsic viscosity of 0.8 dl / g an intrinsic viscosity of about 0.7 dl / g after recycling.
  • It are processes for producing cellular upholstery articles, the objects itself and machines for making cellular cushioning articles. A preferred cushioning article has discrete independent cells from lamination (preferably by heat sealing) of two continuous ones Plastic film materials together to form a unitary cellular laminate to build. In the manufacture of this item will be at least heated one of the continuous plastic film materials and then by means of a matrix cylinder or other suitable means designed to form a plurality of individual cells or pockets (i.e., shaped). When subsequent sections of the film are formed become, the surface becomes of the base portion surrounding each cell at a melting temperature held, and the second film is on a similar Temperature warmed up and applied to the base portion of the first film to to form a unitary structure, with each (each) of the molded Sections or cells individually to form a variety discrete chambers, d. H. Cells permanently sealed in it Air or other fluid contained, is sealed. Although others Method can be used To glue the films together, it has been found that this Heat fusion giving the best results or more reliable and durable products produced.
  • A alternative preferred embodiment also uses two discrete continuous (preferably flat, d. H. unshaped) films laminated together in a pattern are, the inflatable chambers, inflatable channels, connecting passages and optionally one or more inflation manifolds and an inflation rim region Are defined. After the foils have been sealed together, can the chambers are inflated and the inflation channels are sealed to the Include inflation gas or fluid, whereby in the laminate cushion chambers, d. H. Bubbles, be provided.
  • 1 FIG. 11 is an exploded perspective view illustrating a preferred cushioning article. FIG 10 with a formed (molded) first film 12 and an unshaped flat lamination film 14 illustrated. The first slide 12 has discrete sections formed 16 on that as protrusions 16 from the flat base 18 peaking. The trained sections 16 have a circular cross-section, ie a circular "footprint" and a flat upper area. It goes in 1 from the distance of discretely formed sections 16 that the object 10 Can provide cushioning effect to an object that is subject of 10 should be surrounded. Because both the first slide 12 as well as the second foil 14 flexible foils, goes out of the distance of discretely shaped sections 16 and the basic section 18 that the object 10 also has flexibility so that it can be wrapped around an object to be protected.
  • 2 illustrates a cross-sectional view of the fully assembled article 10 , Preferably, a permanent hermetic heat seal is made between the base portion 18 the first slide 12 with the contacting portions of the laminating film 14 produced. The resulting article provides excellent cushioning and shock absorption. The side walls of the molded sections 16 preferably taper, so that the thinnest portion of the wall furthest from the lamination 14 is removed, as in US 3,294,387 is discussed.
  • The shaped sections 16 can be made from any desired shape or configuration with uniform or tapered walls. Although the shaped sections 16 are shown with a circular cross section and a flat upper portion, particularly preferred shaped portions have a circular cross-sectional shape with an upper dome.
  • Preferably, the first and second films have an A / B / C / B / A structure. In a particularly preferred embodiment, the A layers serve as heat seal and protective layers and together make up 86% of the total thickness, each of the B layers make up 2% of the total thickness, and the C layer accounts for 10% of the total thickness. De C layer serves as an O 2 barrier layer and is obtained from 100% post consumer PET grade NLP Clear having an intrinsic viscosity of 0.71 dl / g, a melting point of 246 ° C and a crystallinity of 36% Phoenix Technologies, Bowling Green, Ohio, USA. Each of the B layers serve as tie layer, and is made of 100% Plexar PX3236 anhydride modified linear ® Polye low density ethylene copolymer, obtained from Equistar. Each of the A layers is by weight of a mixture of 45.% HCX002 linear low density polyethylene having a density of 0.941 g / cm 3 and a melt index of 4, obtained from Mobil, 45 wt.% LF10218 low density polyethylene having a density of 0.918 g / cm 3 and a melt index of 2, obtained from Nova, and 10 wt% SLX9103 metallocene catalyzed ethylene / butene / hexene terpolymer, obtained from Exxon.
  • The shaped first film 12 preferably has a thickness (before molding) from 25.4 to 101.6 μm (1 to 4 mils), especially 30.5 to 50.8 μm (1.2 to 2 mils), in particular about 38.1 microns (1.5 mils). Flat laminating film preferably has a thickness from 12.7 to 50.8 microns (0.5 to 2 mils), especially 12.7 to 38.1 μm (0.5 to 1.5 mils), in particular 25.4 μm (1.0 mil). The "bubble" in the cushion item preferably has a height from 3.2 to 25.4 mm (1/8 inch to 1 inch) and a diameter (or major dimension) from 3.2 to 76.2 mm (1/8 in. to 3 in.). The bubble height is in particular 6.4 to 12.7 mm (1/4 to 1/2 inch), and the bubble diameter is 6.4 to 25.4 mm (1/4 inch to 1 inch). When the height and the diameter of the Bubble increases is preferably the thickness of the first and second films greater. The first film is preferably thicker than the second film.
  • In Certain cases it may be desirable to have a molded film with a fairly thin film thickness, for example, films of the order of magnitude from 0.025 to 0.127 mm (1 to 5 thousandths of an inch) while the support film (Back sheet) can be relatively stiff to give the structure a hold. It can thus Variants in any number of the thickness of the sealed films and the size and configuration the shaped sections are made to have any desired shock absorbing effect to obtain.
  • 3 is a schematic of a particularly preferred device and a particularly preferred method 20 for producing the inflatable cushioning article of the invention. In 3 illustrate extruders 22 and 24 the first slide 26 or the second film 28 , After extrusion, the first film is 26 partly tempering rolls 30 and 32 preferably having a diameter of 20.3 cm (8 inches) and maintained at a surface temperature well below the melting temperature of the extrudate, e.g. B. 37.8 to 121.1 ° C (100 to 250 ° F). The annealing rollers allow the film to cool to the solid state, but keep the film sufficiently warm to contact the forming roll 34 to be molded. The first slide 26 when it comes to contact with the second roller 32 loses, in contact with vacuum forming roll 34 which does not need to be heated, but is preferably heated to about 37.8 ° C (100 ° F). The first slide 26 contacts the forming roll 34 over at least a portion (preferably the entire) vacuum zone 36 during which time sections of the first film 26 by means of vacuum in respective cavities in the surface of the forming roll 34 be pulled, causing the in 1 illustrated shaped sections 16 to be produced. The size and shape of the cavities in the forming roll 34 determine the size and shape of the molded sections on the first slide 26 ,
  • As in 3 illustrated, becomes vacuum zone 36 from the inside of the forming roll 34 applied and is constant at that portion of the forming roll 34 created in the in 3 is shown position. This means that vacuum is applied to the running section of the forming roll 34 is applied, which is above the specified vacuum zone 36 located when the forming roll 34 rotates.
  • When the now formed first slide 26 through the gap 38 between the forming roll 34 and the pressure roller 40 Moves, she is using the second slide 28 fresh from extruder 24 brought together. The first and second slide 26 and 28 while they are in split 38 are in a hot state to sammengepresst. The compression of the films 26 and 28 leads together with the continuous heating of the films 26 and 28 when together about half way around the heated forming roll 34 traveled around and the second gap 42 between forming roll 34 and take-off roll 44 have happened to a hermetic heat seal between the base section 18 (please refer 1 and 2 ) of the first film 26 and a corresponding portion of the second sheet 28 , whereby cushioning object 10 is obtained. The take-off roll 44 pulls the cushioning article from the forming roll 34 down.
  • 4 Figure 11 is a schematic exploded view of a portion of an alternatively laminated inflatable article made in accordance with the present invention 50 , 5 Fig. 12 is a plane view of the above fully assembled laminated inflatable article 50 , In the 4 and 5 together in 4 the pattern of the heat seal is not included for ease of illustration) includes the inflatable cushioning article 50 the first slide 52 placed in a heat seal pattern on the second foil 54 has been heat sealed, creating a plurality of "dead end" inflatable passages and an open perimeter along the length of an edge of the inflatable article 50 in the machine direction. Each passage with dead end contains a variety of inflatable air chambers 56 in series through inflatable connection channels 58 are connected and in the terminal air chamber 60 ends. The inflatable cushion object 50 has the continuously heat-sealed section 62 on. The inflatable cushion object 50 also has a continuous non-sealed portion which defines the open edge portion 64 includes, as well as the inflatable air chambers 56 and 60 and the inflatable connection channels 58 on. The heat-sealed section 62 is along the machine direction of the inflatable cushion article 50 continuous, with the sealed section 62 a preferred raised surface pattern of the roll 88 with increased surface area (see 6 ) corresponds. The unsealed section 58 is also object along the machine direction 50 continuous, wherein the complementary non-sealed portion has a preferred surface pattern with recesses (ie background pattern) of a roll 88 with a raised surface (see again 6 ) corresponds. Optionally, the non-sealed portion may further include a machine direction passage (not shown) serving as a manifold, ie, each of the passages 58 along an open edge area of the object. The open border area 64 however, it is preferred.
  • 6 is a schematic of a preferred device and method 68 for the production of inflatable article 50 in the 4 and 5 is shown. In 6 extrude extruder 70 and 72 the first slide 74 or the second film 76 , After extrusion, there was film 74 partly around heat transfer (cooling) roll 78 preferably having a diameter of 20 cm (8 inches) and maintained at a surface temperature well below the melting temperature of the extrudate, e.g. B. 37.8 to 65.6 ° C (100 to 150 ° F). The second slide 76 was partially around each of the heat transfer (cooling) rollers 80 and 82 each having a diameter of 20.3 cm (8 inches) and each at a surface temperature similar to that of chill roll 78 being held. After cooling, the first film was 74 partially (about 90 degrees) around the nip roll 84 which has a diameter of 20.3 cm (8 inches) and the main function is the crimp contact with the heat transfer (heating) roll 88 maintains with increased surface area. The squeezer 84 is a rubber roller with an outer coating of polytetrafluoroethylene (eg Teflon® ). While the first slide 74 over nip 84 is transported, comes the second slide 76 with the first slide 74 together, with both slides together a short distance around squeegee 84 be wrapped around before they get together in the first nip 86 enter. Nipper 84 provides a position at which the slides 74 and 76 come together without being scratched or deformed.
  • The second slide 76 then generates direct contact with roller 88 with increased surface area (which for the sake of simplicity is shown as a smooth roller). The first gap 86 put the slides 74 and 76 a pressure of from 357.2 to 1786 (2 to 10), preferably 357.2 to 1071.6 (2 to 6), more preferably about 714.4 g per cm (4 lb per linear inch).
  • The slides 74 and 76 Contact together over a distance of about 180 degrees roller 88 with increased surface. The roller 88 with raised surface has a diameter of 30.5 cm (12 inches) and is heated by circulating hot oil through it so that the surface is held at a temperature of 139 ° C to 177 ° C (280 ° F to 350 ° F) with the edges of the raised surface rounded to a radius of 0.4 mm (1/64 inch). The role 88 with the increased surface carries a Teflon ® -Polytetrafluorethylenbeschichtung, wherein the elevated surfaces by a distance of 0.64 cm (1/4 inch) above the background. The raised surface of the roller 88 with increased surface area is also provided with a surface roughness of 50 to 500 root mean square (ie "rms"), preferably 100 to 300 rms, in particular about 250 rms. This roughness level improves the separation qualities of the roller 88 with increased surface area, allows faster processing speeds and a high quality product, not by kickback on roller 88 is damaged.
  • The raised surface on roll 88 heats that section of the film 76 she contacts. Heat is from the roller 88 with increased surface area through a heated portion of the film 76 through to a corresponding section of the film 74 to heat the film 76 to be heat sealed. The heated films 74 and 76 when they pass the roller 88 with increased surface to pass through about 180 degrees, together the second nip 90 who heated the films 74 and 76 about the same pressure as he puts in the first nip 86 is applied, resulting in a structured heat seal between the films 74 and 76 leads.
  • After passing the second crimp 90 get slides 74 and 76 which are now sealed together, about 90 degrees around heat transfer (cooling) roll 92 which is 12 inches (30.5 cm) in diameter and is passed through the cooling water with the cooling water at a temperature of 37.8 ° C to 65.6 ° C (100 ° F to 150 ° F). The chill roll 92 has an approximately 0.64 cm (1/4 inch) thick release and heat transfer coating. The coating is made from a composition called "SA-B4" manufactured by Silicone Products and Technologies Inc., Lan caster, NY, USA, and applied to a metal roller. The coating contains silicone rubber, around chill roll 74 having a Shore A hardness of 40 to 100, preferably 50 to 80, especially 50 to 70 and more preferably about 60 to provide. The SA-B4 composition also contains one or more fillers to increase the thermal conductivity, hence the ability of the chill roll 92 to cool the still hot foils which are now sealed together to form an inflatable article 94 which is then rolled up to form a roll for transport and subsequent inflation and sealing.
  • To perform the process at a relatively high speed, z. B. Speeds of at least 120 feet per minute, preferably 45 to 91.4 meters (150 to 300 feet) per minute, but up to as high as 152.4 meters (500 feet) per minute , It has proven to be important to provide the manufacturing device with multiple features. First, the roller should 88 with a raised surface provided with a release coating or layer, and also sharp edges should be avoided, which interfere with a clean separation of the film from the roller with increased surface. As used herein, the term "release coating" includes all release coatings and layers, including multiple-ply coatings, applied coatings such as brushed and sprayed coatings that cure on the roll, and even a release tape bonded to the roll. A preferred release coating composition is Teflon ® polytetrafluoroethylene. Second, the edges of the raised surfaces should be rounded to a radius large enough to allow the film to easily dislodge without sticking to the edge because of its "sharpness" relative to the softened film. The radius of curvature is preferably 0.1 to 9.5 mm (1/256 inch to 3/8 inch), more preferably 0.2 to 1.6 mm (1/128 inch to 1/16 inch), especially 0.25 mm to 0.8 mm (1/100 inch to 1/32 inch) and more preferably about 0.4 mm (1/64 inch). It is also important to provide the chill roll downstream of and in pinch relationship with the raised surface roll with a release coating or layer as described above.
  • The method and apparatus used in 6 can also be supplemented with additional optional components and stages. One or both of the slides 74 and 76 may be preheated to a temperature below its melting temperature (s), such that from the roll 88 With increased surface area less heat must be supplied. In this way, the process can be carried out at a higher speed, and / or the heat seal can be made stronger or otherwise superior. The preheating can be carried out, for example, by squeegee 84 provided with heating characteristics, in addition to the equipment of the roller 88 with increased surface with heating characteristics. Additional pinch points against the raised surface roll may optionally be provided to provide further pressure points to form strong heat seals at high manufacturing speeds.
  • An important advantage of the inflatable cushioning article 50 opposite cushioning object 10 lies in the fact that the inflatable cushion object 50 in the uninflated state can be transported as a relatively high density intermediate ready to inflate at the site of end use.
  • A particularly preferred film from which the inflatable cushioning article 50 are the A / B / C / B / A films already described, ie in terms of number of layers, relative layer thicknesses and layer composition. In the inflatable cushion object 50 Preferably, both films have the same thickness. Depending on the desired end use and the size of the inflatable chambers, the thickness of each film is preferably 0.5 to 20 mils, more preferably 12.7 to 101.6 microns (0.5 to 4 mils). , in particular 25.4 to 76.2 μm (1 to 3 mils), especially 38.1 μm (1.5 mils).
  • The inflated chambers preferably have a diameter of 19.1 to 101.6 mm (0.75 to 4 inches), especially 25.4 to 50.8 mm (1 up to 2 inches). It is preferred that both films have a thickness of 25.4 to 101.6 microns (1 to 4 mils), especially 30.5 to 50.8 μm (1.2 to 2 mils), especially about 38.1 μm (1.5 mils). The inflated chambers of the cushioning article preferably have a height from 1.6 to 50.8 mm (1/16 inch to 2 inches), especially 1.6 to 25.4 mm (1/16 to 1 inch), especially 1.6 to 12.7 mm (1/16 inch to 1/2 inch). The inflated chambers preferably have one Diameter of 25.4 to 101.6 mm (1 to 4 inches), especially 25.4 to 76.2 mm (1 to 3 inches), especially 25.4 to 50.8 mm (1 to 2 inches).
  • ever bigger the Chamber size is, the thicker are generally the preferred films. The for the production The film used for the cushioning article is preferably as thin as possible in order to to minimize the amount of resin required to make the article. However, the film must also be thick enough to allow the padded article to be padded required durability for the desired end use to rent. Another consideration in the preparation according to the invention of the cellular Materials is that provides further shock resistance effect becomes when the thickness of the films is increased.
  • The Foils, if desired or required, also added various additives. additives include, for example, pigments, colorants, fillers, Antioxidants, flame retardants, antibacterial agents, antistatic agents, Stabilizers, fragrances, odor masking agents, antiblocking agents, Lubricant and the like. The present invention thus comprises the use of suitable film components.
  • The Inflatable invention Cushioning articles Resist rupture when pressure on a limited area exercised is because the air ducts between the chambers for provide a cushioning effect. The laminates also show excellent creep resistance and upholstery properties because the air passes along the passages between can move the bubbles.
  • The various terms and phrases used in this document are intended to have their usual meaning which those skilled in the art will appreciate (see also US Pat US 6,333,061 by Vadhar entitled "Packaging Article", issued December 25, 2001).

Claims (26)

  1. A cellular cushioning article comprising (A) a first multilayer film having first and second outer layers each containing an olefin-based polymer and an inner O 2 barrier layer, and (B) a second multilayer film having first and second outer layers, each one An olefin-based polymer and an inner O 2 barrier layer, wherein at least the inner O 2 barrier layer of the first multilayer film or the inner O 2 barrier layer of the second multilayer film comprises recycled polyester and the first multilayer film is laminated to the second multilayer film in that a plurality of cells are formed between the first multilayer film and the second multilayer film.
  2. The cellular cushioning article of claim 1 wherein both the first inner O 2 barrier layer and the second inner O 2 barrier layer comprise recycled polyester.
  3. cellular A cushioning article according to claim 1 or 2, wherein (A) the outer layers the first slide in each case at least one member selected from the group consisting of low density polyethylene, linear Low density polyethylene, very low density polyethylene and homogeneous ethylene / α-olefin copolymer include, and (B) the outer layers the second film is selected from at least one member the group consisting of low density polyethylene, linear Low density polyethylene, very low density polyethylene and homogeneous ethylene / α-olefin copolymer include.
  4. The cellular cushioning article of claim 3, wherein: (A) the first film further comprises a first interconnecting layer between the first outer layer and the O 2 barrier layer and a second interconnecting layer between the second outer layer and the O 2 barrier layer, and (B) the second film further comprises a third interconnect layer between the first outer layer and the O 2 barrier layer and a fourth interconnect layer between the second outer layer and the O 2 barrier layer.
  5. cellular A cushioning article according to claim 4, wherein the first connection layer at least one member selected selected from the group consisting of anhydride-modified ethylene / α-olefin copolymer, Ethylene / unsaturated Ester copolymer and ethylene / unsaturated acid copolymer; the second link layer at least one member selected from the group consisting of anhydride-modified ethylene / α-olefin copolymer, ethylene / unsaturated Ester copolymer and ethylene / unsaturated acid copolymer; the third link layer at least one member selected from the group consisting of anhydride-modified ethylene / α-olefin copolymer, Ethylene / unsaturated Ester copolymer and ethylene / unsaturated acid copolymer, and the fourth link layer at least one member selected from the group consisting of anhydride-modified ethylene / α-olefin copolymer, ethylene / unsaturated Ester copolymer and ethylene / unsaturated acid copolymer.
  6. cellular Upholstered article according to one of the preceding claims, in the first multilayer film is a flat, unshaped film and the second multilayer film is a flat, unshaped film.
  7. cellular A cushioning article according to claim 6, wherein the first and second Foil are sealed together to a variety of cell rows, wherein each of the cell rows contains a plurality of cells, and one passage to form, which connects the cells in series, wherein the Rows have a dead end, the passage and the cells in the Rows are inflated by an inflation fluid, the passage sealed by sealing, leaving the cells in the row stay inflated.
  8. Cellular cushioning article according to one of Claims 1 to 5, wherein a plurality of discrete cavities are formed at spaced intervals in the first film, between which a base portion is located, and the second film is a flat film adhered to the first film in the base portion, wherein the first and second foils include a fluid in each of the discrete cavities.
  9. cellular A cushioning article according to any one of claims 1 to 5, wherein a plurality of discrete cavities at spaced intervals in both the first slide and are formed in the second film, each of the films has a basic area between the discrete cavities has, at least a portion of the basic areas of the films together is glued and the cavities the first and second foils contain a fluid.
  10. A cellular cushioning article according to any one of the preceding claims, wherein the recycled polyester is present in the inner O 2 barrier layer of the first multilayer film or the inner O 2 barrier layer of the second multilayer film in an amount of 10 to 100%, based on that described in U.S. Patent Nos Layer of existing polyester.
  11. A cellular cushioning article according to any one of the preceding claims, wherein the recycled polyester is present in the inner O 2 barrier layer of the first multilayer film or the inner O 2 barrier layer of the second multilayer film in an amount of 30 to 100%, based on that described in U.S. Patent Nos Layer of existing polyester.
  12. A cellular cushioning article according to any one of the preceding claims, wherein the recycled polyester is present in the inner O 2 barrier layer of the first multilayer film or the inner O 2 barrier layer of the second multilayer film in an amount of 60 to 100%, based on that described in U.S. Patent Nos Layer of existing polyester.
  13. A cellular cushioning article according to any one of the preceding claims, wherein the recycled polyester is present in the inner O 2 barrier layer of the first multilayer film or inner O 2 barrier layer of the second multilayer film in an amount of 100% based on that present in the layer Polyester.
  14. A cellular cushioning article according to any one of claims 1 to 12, wherein the O 2 barrier layer comprises a blend of recycled polyethylene terephthalate and virgin polyethylene terephthalate.
  15. cellular Upholstered article according to one of the preceding claims, in the recycled polyester recycled polyester with a structural viscosity of less as or equal to 0.8 deciliters per gram.
  16. cellular A cushioning article according to any one of claims 1 to 14, wherein the recycled polyester is recycled polyester having a shear thinning from 0.8 to 1.25 deciliters per gram.
  17. cellular Upholstered article according to one of the preceding claims, in the first film has a thickness of 5.1 to 254 μm (0.2 to 10 mils) and the second film has a thickness of 5.1 to 254 μm (0.2 to 10 mils).
  18. A method of manufacturing the cushioning article according to any one of the preceding claims, wherein (A) a first multilayer film is extruded with first and second outer layers each containing an olefin-based polymer and an inner O 2 barrier layer, and (B) a second multilayer film is extruded with first and second outer layers each containing an olefin-based polymer and an inner O 2 barrier layer, and (C) the first and second multilayer films are adhered to each other to form a plurality of cells, and wherein the inner O 2 barrier layer of the first multilayer film or the inner O 2 -Barriereschicht the second multi-layer film contains recycled polyester.
  19. The method of claim 18, further comprising a Variety of discrete cavities is formed at spaced intervals in the first sheet, between which is a basic area where the molding is performed, however, after the first multilayer film has been extruded before the first multilayer film is adhered to the second multilayer film with the base region of the first film attached to the second Foil is glued, leaving the first and the second foil, though the first and second multilayer films are glued together, together include a fluid in each of the discrete cavities.
  20. A method according to claim 19, wherein the molding is carried out by putting the slide over a forming roll is passed, the discrete areas of the film in molding cavities pulls by the atmosphere evacuated from areas between the film and the molding cavity becomes.
  21. A method according to claim 19 or 20, wherein said Fluid is air.
  22. The method of claim 18, further comprising forming a plurality of discrete voids in each of the first multilayer film and the second multilayer film, wherein the plurality of discrete voids are at spaced intervals with a root area therebetween, the molding is performed after the first and second multilayer films have been extruded, but before the first multilayer film has been bonded to the second multilayer film, the base region of the first film being bonded to the base region of the second film, such that the first and second Film, when the first and second multilayer films are adhered together, together include a fluid in each of the discrete voids.
  23. The method of claim 22, wherein the fluid is air is.
  24. A method according to claim 22 or 23, wherein the Basic region of the first film to the base region of the second film heat sealed becomes.
  25. The method of claim 19, wherein the first and second foil heat sealed together be around an inflatable cushion object with a row of cells, each of the rows of cells forming a plurality of cells and a passageway that holds the cells together connects, each row of cells having a dead end, wherein the passage and the cells in the rows through an inflation fluid can be inflated, and the passage can be closed by sealing, so that the Cells in the row remain inflated.
  26. The method of claim 25, wherein the inflatable Upholstered article along a machine direction edge has open edge area.
DE60317589T 2002-02-25 2003-02-20 Air cushion laminate with a barrier layer of recycled polyester Active DE60317589T2 (en)

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US82635 2002-02-25
US10/082,635 US20030161999A1 (en) 2002-02-25 2002-02-25 Laminated cushioning article having recycled polyester barrier layer

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DE60317589D1 (en) 2008-01-03
EP1338413A1 (en) 2003-08-27
ES2295472T3 (en) 2008-04-16
EP1338413B1 (en) 2007-11-21
US20030161999A1 (en) 2003-08-28

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